KR20180006385A - APPARATUS AND METHOD FOR MANUFACTURING METAL POWDER MATERIAL - Google Patents

Abstract

The present invention relates to a method for producing a metallic powder material comprising the steps of feeding a feed material to a melting hose and melting the feed material in the melting hose with a first heat source to provide a molten material having a desired chemical composition . At least a portion of the molten material is passed directly or indirectly from the melting hose to the atomizing hose, and the molten material is heated to the second heat source. At least a portion of the molten material is passed from the atomizing hose to the atomization apparatus in a molten state to form a droplet spray from the molten material. At least a portion of the droplet spray is cured to provide a metallic powder material.

Description

APPARATUS AND METHOD FOR MANUFACTURING METAL POWDER MATERIAL

The present invention relates to a method and apparatus for producing a metallic powder material. In particular, certain non-limiting embodiments of the present invention provide a method of making a metallic powder material using a device comprising a melting hose configured to receive a feed material and an atomizing hose arranged to receive at least a portion of the molten material from the melting hose, And a method for manufacturing the same. In certain non-limiting embodiments of the method according to the present invention, the method includes passing at least a portion of the molten material from the atomizing hose to a molten state in an atomizing device, wherein the atomizing device comprises an atomizing nozzle . The present invention also relates to articles and metallic powder materials produced by the method and apparatus of the present invention.

Gas atomization and hot isostatic pressing techniques (also referred to as "HIPing") are commonly used to form metallic articles from metallic powder materials. In this process, a melt having a desired chemical composition is prepared, and the molten composition is passed through an atomizing device in which a gas jet is sprayed with a droplet of the molten composition, The droplets are quenched. The cooled droplets form a loose powder. The metallic powder material can be sintered under hot hydrostatic pressure to form a metallic article.

Another prior art method for making metallic articles is nucleated casting. The nucleation casting method uses gas atomization to form a spray of semi-liquid droplets deposited in a mold. It is generally seen that some portion of the droplet spray, i. E., Overspray, can accumulate on the upper surface of the mold. Similar to the nucleation casting process, spray forming which forms a metallic article from a semi-liquid droplet spray but does not require the use of a mold is also a prior art technique.

In prior art nucleation methods, spray molding methods, and gas atomization / HIPing processes, the solidified material, which has previously been melted in the desired chemical composition, is re-melted and the molten material is passed to the atomizing device. In one example, the cured material with the desired chemical composition is thermomechanically worked on the wire and then re-melted for atomization. In another example, a cold-wall induction furnace is used to melt and homogenize the pre-cured material before the atomization process. If the material is cured before being re-melted and atomized, the material may become contaminated, for example during thermal machining and handling steps. Contaminants in the solid material are entrained in the molten metal stream contained in the atomization device. In addition, materials that are re-melted and hardened for atomization can limit the ability to control process parameters, such as molten metal superheat and flow rate, There may be a need to adjust to ensure. Further, for re-melting and atomization, the use of a cured material can increase the cost of manufacturing the atomized metal powder.

The present invention relates, in part, to a method and apparatus for solving certain disadvantages of the prior art for producing metallic powder material. One non-limiting aspect of the present invention relates to a method for making a metallic powder material, the method comprising: feeding a feed material to a melting hearth; Melting a feed material in the melting hose with a first heat source to provide a molten material having a desired composition; Passing at least a portion of the molten material through an atomizing hearth; Heating the molten material in the atomization hose as a second heat source; Passing at least a portion of the molten material from the atomization hose to a molten state, directly or indirectly, to the atomization apparatus; And forming a droplet spray of the molten material with the atomization device. At least a portion of the droplet spray is cured to provide a metallic powder material. In certain non-limiting embodiments of the method, at least a portion of the molten material is passed continuously into the atomization apparatus. In certain non-limiting embodiments of the method, the molten material is passed from the melting hose to the atomizing hose through one or more additional hoses.

Another non-limiting aspect of the present invention relates to an apparatus for manufacturing a metallic powder material. The apparatus comprises: a melting hose configured to receive a feed material; A first heat source configured to melt the feed material within the melting hose to provide a molten material having a desired composition; An atomizing hose arranged to receive directly or indirectly at least a portion of the molten material from the melting hose; A second heat source configured to heat the molten material in the atomization hurdle; An atomization device configured to form a droplet spray of molten material; An atomizing hose and a delivery unit coupled to the atomizing device; And a collector configured to receive a droplet spray from the atomization apparatus. The delivery unit is configured to pass the molten material from the atomization hose to the atomization apparatus in a molten state.

The features and advantages of the methods and alloy articles described herein may be better understood with reference to the accompanying drawings, in which:
1 is a flow chart of one non-limiting embodiment of a method of making a metallic powder material according to the present invention;
2 is a cross-sectional view schematically illustrating a non-limiting embodiment of an apparatus for manufacturing a metallic powder material according to the present invention;
Figure 3 is a schematic plan view of the device of Figure 1;
4 is a schematic top view of yet another non-limiting embodiment of an apparatus for manufacturing a metallic powder material according to the present invention;
Figure 5 is an enlarged partial cross-sectional view of the device of Figure 1; And
6 is a cross-sectional view schematically illustrating yet another non-limiting embodiment of an apparatus for manufacturing a metallic powder material according to the present invention.
It is to be understood that the invention is not limited to the embodiments illustrated in the foregoing brief description of the drawings. Those skilled in the art will recognize other details as well as the details described above by considering the following detailed description of certain non-limiting embodiments of apparatus and methods according to the present invention. In addition, those skilled in the art will recognize such specific details when using the apparatus and methods described herein.

In the non-limiting embodiments and claims of the invention, in the non-operational examples or in the examples not otherwise indicated, all numbers representing features or quantities of components and products, process conditions, etc., It can be understood that it can be transformed into "drug ". Accordingly, unless indicated to the contrary, any numerical parameters set forth in the following specification and claims can be varied according to the desired properties desired to be implemented in the apparatus and method according to the present invention. At the very least, it is to be understood that each numerical parameter is not intended to limit the scope of the appended claims to the scope of the claims, but is dependent upon the valid values applying ordinary general techniques.

The present invention relates, in part, to an apparatus and method for solving the limitations presented in prior art methods for producing metallic powder materials. Turning to Fig. 1, a non-limiting embodiment of a method of making a metallic powder material is illustrated. The method comprising: feeding the feed material to the melting hose (step 100); Melting the feed material in the melting hose with a first heat source to produce a molten material having a desired chemical composition (step 110); Passing at least a portion of the molten material directly or indirectly to the atomizing hose (step 120); Heating the molten material in the atomizing hose with the second heat source (step 130); Passing at least a portion of the molten material directly or indirectly through the atomizing hose (step 120); Passing at least a portion of the molten material from the atomizing hose to the atomization apparatus in a molten state (step 140); And forming a droplet spray of molten material into the atomization apparatus (step 150). At least a portion of the droplet spray is solidified to provide a metallic powder material with the desired composition.

Limiting example of an apparatus 200 for making a metallic powder material is shown in Figure 2-3 in a melting chamber 210, a melting hose 220 and a first heat source 230 ). The melting chamber 210 is configured to maintain an atmosphere therein. The atmosphere may have a pressure below atmospheric, or a pressure above atmospheric, or at atmospheric pressure. According to certain non-limiting embodiments, the gas atmosphere in the melting chamber 210 may be chemically inert with respect to the heated material in the melting chamber 210. According to certain non-limiting embodiments, the gas atmosphere in the melting chamber 210 may be a mixture of helium, argon, helium and argon, or another inert gas or gas mixture. According to other non-limiting embodiments, other gases or gas mixtures may be introduced into the atmosphere of the melting chamber 210, assuming that the gas or gas mixture does not significantly contaminate the molten material within the melting chamber 210 have.

The melting hose 220 is configured to receive the feed material 240. According to certain non-limiting embodiments, the feed material 240 is a virgin raw material. According to other non-limiting embodiments, the feed material 240 comprises or consists of a scrap material, a revert, a recycling material, and / or a master alloy . According to certain non-limiting embodiments, the feed material 240 comprises a particulate material. According to other non-limiting embodiments, the feed material 240 may be a material that is fabricated or previously melted in the form of an electrode, for example, a previously melted material in the form of a cylinder or rectangular prism And / or < / RTI > In any case, in the process according to the invention, the chemical composition of the molten material produced in the melting hose 220 is adjusted to the desired composition by selectively adding the feed material to the melting hose 210.

According to certain non-limiting embodiments, the feed material 240 comprises mostly titanium material. According to certain non-limiting embodiments, the feed material 240 may be a commercially pure titanium, a titanium alloy (e.g., a Ti-6Al-4V alloy having a composition specified in UNS R56400), and a titanium alumina (For example, a Ti-48Al-2Nb-2Cr alloy). According to another non-limiting embodiment, the feed material 240 is selected to provide a molten material comprising, by weight, about 4% vanadium, about 6% aluminum, residual titanium, and impurities. (All percentages herein are% by weight, unless otherwise indicated). According to another non-limiting embodiment, the feed material 240 may be selected from the group consisting of industrial pure nickel, nickel alloys (e.g., alloy 718 having a composition specified in UNS N07718), pure zirconium for industry, zirconium alloys (For example, ATI Nb1Zr (TM) alloys (Type 3 and Type 4) having a composition specified in UNS R04261), pure tantalum for industrial use, tantalum alloys (for example, those specified in UNS 20255 A tantalum-10% tungsten alloy having a composition of the composition of the present invention), pure tungsten for industry, and a tungsten alloy (e.g., a 90-7-3 tungsten alloy). It will be appreciated that the apparatus and methods described herein are not limited to materials of manufacture having the above-mentioned chemical composition. Instead, the starting material may be selected to provide a molten composition having the desired chemical composition and other desired properties. In the apparatuses and methods described herein, the molten material is atomized, thereby providing a metallic powder material having the chemical composition of the molten material atomized into a powder.

According to certain non-limiting embodiments, the feed material 240 is fed into the melting hose 220 via a feed mechanism, for example, a feed chute 250. According to certain non-limiting embodiments, the feed mechanism comprises at least one of a vibratory feeder, a chute, and a pusher. In other non-limiting embodiments, the feed mechanism includes any other mechanism capable of properly feeding the feed material 240 onto the melting hose 220.

According to certain non-limiting embodiments, the first heat source 230 associated with the melting hose 220 may be a plasma torch, a heating device selected from an electron beam generator, another heating device generating electrons, A laser, an electric arc device, and an induction coil. In one example, the first heat source 230 is configured to melt the feed material 240 in the melting hose 220 using a plasma torch to produce a molten material 260 having a desired chemical composition. The first heat source 230 is configured to heat the feed material in the melting hose 220 to at least the melting temperature (liquidus) of the feed material 240 and maintain the materials in a molten state within the melting hose 220 Respectively. In certain non-limiting embodiments, the first heat source 230 heats the molten material formed in the melting hose 220 to refine the molten material at least in part. According to certain non-limiting embodiments, the first heat source 230 may be located about 100 mm to about 250 mm above the upper surface of the melting hose 220. According to other non-limiting embodiments, the first heat source 230 includes a first plasma torch positioned within the melting hose 220 at a constant height relative to the upper surface of the molten material, The edge of the plume of hot plasma formed by the torch appropriately heats the material. According to certain non-limiting embodiments, the power level, the position relative to the melting hose 220, and other variables of the first heat source 230, 260) is heated to a temperature range from the liquidus line of the material to about 500 DEG C above the melting point of the material. According to additional embodiments, the power level, location, and other variables of the first heat source 230 may be adjusted such that the material in the melting hose 220 is heated to about 300 degrees Celsius above the liquidus line of material at a temperature above about 50 degrees Celsius of the liquidus line of material Lt; RTI ID = 0.0 > of < / RTI > According to other embodiments, the power level, position, and other variables of the first heat source 230 may be adjusted such that the first heat source 230 alters the chemistry of the molten material in an undesired manner and / Unless evaporated, it is optimized to overheat the material to a temperature in excess of the liquidus line of the material to any suitable degree.

According to certain non-limiting embodiments, the atomizing hose 270 is arranged to be received in at least a portion of the molten material 260, directly or indirectly, from the melting hose 220. Once molten and appropriately heated, the molten material 260 within the melting hose 220 may exit the melting hose 220 (e.g., through one or more additional hoses) and be passed to the atomizing hose 270. The atomizing hose 270 collects the molten material 260 directly or indirectly from the atomizing hose 270 so that the molten material 260 is directed to at least a portion of the molten material 260 as it passes from the atomizing hose 270 And may be located on the atomizing nozzle of the atomization apparatus 310, which will be further described below. In this regard, the atomization hose 270 acts as a "surge buffer " for the molten material 260 to regulate the flow of the molten material 260 to the atomization device 310. According to certain non-limiting embodiments, an atomizing hose 270 is arranged in a melting chamber 210 having a melting hose 220. According to other embodiments, the atomization hose 270 is not located in a single chamber having a melting hose 220 but may be located in another chamber, such as an adjacent chamber.

According to various non-limiting embodiments, one or more additional hoses may be arranged between the melting hose 220 and the atomizing hose 260, and the molten material may be supplied from the melting hose 260 via one or more additional hoses, 270). In this specification, such a configuration includes indirectly passing the molten material from the melting hose to the atomizing hose.

Referring to Figure 5, according to certain non-limiting embodiments, the melting hose 220 and the atomization hose 270 are both water cooled copper horses. Also, if provided, one or more additional hoses provided in various non-limiting embodiments may be water cooled copper horses. According to other non-limiting embodiments, one or more of the melting hose 220, the atomizing hose 270, and, if provided, one or more of the one or more additional hoses may be formed of any other suitable material And is configured to prevent the hose from melting when the material is heated inside or otherwise cooled. According to certain non-limiting embodiments, a portion of the molten material 260 is contacted with the cooled wall of the melting hose 220 and cured so that the remainder of the molten material 260 is molten A first skull 280 is formed to prevent the wall of the melting hose 220 from contacting the wall of the melting furnace 220 so that the wall of the melting hose 220 can be insulated from the molten material 260. A portion of the molten material 260 is in contact with the cooled wall of the atomizing hose 270 as the molten material 260 flows from the melting hose 220 into the atomizing hose 270, A second skull 290 is formed that is cured on the wall to prevent the remainder of the molten material 260 from contacting the walls of the atomizing hose 270 so that the wall of the atomizing hose 270 is in contact with the molten material 260, . ≪ / RTI > In certain non-limiting embodiments, the one or more additional hurses, if provided, may be operated in a similar manner to prevent undesirable contact of the molten material with the horses walls.

Depending on the preferred embodiment or use requirements for the particular method or apparatus 200, the melt hose 220, the atomizing hose 270, and, if provided, one or more additional hirs material, And / or modified. For example, for a molten material to be modified, a solid inclusion of high density and other solid contaminants in the molten material may sink into the bottom of the molten material in a particular hose and be incorporated into the skull It is entrained. Some low density solid inclusions or other solid contaminants can float on the surface of the molten material in a particular hose and can be evaporated by the connected heat source. Other low-density solid inclusions or other solid contaminants may be neutrally buoyant suspended somewhat below the surface of the molten material and dissolved in the molten material in the hull. In this manner, the molten material 260 is modified as solid inclusions and other solid contaminants are removed or dissolved from the molten material 260.

4, according to the illustrated non-limiting embodiment, one or more additional hoses 292 are positioned between the melting hose 220 and the atomizing hose 270. As shown in Fig. Passes through one or more additional hose (s) 292 before at least a portion of the molten material 260 on the melting hose 220 is passed into the atomizing hose 270. In certain non-limiting embodiments, the additional hose (s) 292 may be used for one or more of the materials of the molten material 260 that are modified and homogenized. The terms "refining" and "homogenizing" are terms used in the prior art and will be readily apparent to those skilled in the art of metallic powder material manufacturing. Generally, with respect to the Hus components, such modification can be achieved by removing, dissolving, or capturing undesirable components or impurities from the molten material in the hose such that impurities or undesirable components proceed to the sub- ≪ / RTI > Homogenization may include mixing or mixing the molten material so that the material has a more uniform composition. According to certain non-limiting embodiments, one or more additional hose (s) 292 are positioned in series with the atomizing hoses 220, 270 to be melted to form a generally straight molten material 260, or alternatively provides a path in the form of an alternative selected from a generally jig-jagged path, generally an L-shaped path, and generally a C-shaped path. According to certain non-limiting embodiments, an additional heat source (not shown) is coupled to one or more of the additional hose (s) 292. According to certain non-limiting embodiments, the additional heat source includes a plasma torch, one or more heating devices selected from an electron beam generator, another heating device generating electrons, a laser, an electric arc device, and an induction coil do.

According to certain non-limiting embodiments, a second heat source 300 is configured to heat the molten material 260 within the atomization hose 270. According to certain non-limiting embodiments, the second heat source 300 includes a plasma torch, one or more heat sources selected from electron guns, a heating device to generate electrons, a laser, an electric arc, and an induction coil. The second heat source 300 is positioned to heat the upper surface of the molten material within the atomization hose 270 to at least the melting temperature of the material (liquidus line). According to certain non-limiting embodiments, the second heat source 300 may be located about 100 mm to about 250 mm above the atomization hose 270. According to certain non-limiting embodiments, the second heat source 300 includes a plasma torch positioned within the atomization hose 270 at a constant height relative to the upper surface of the molten material, and the plume of hot plasma The edges heat the material appropriately. According to certain non-limiting embodiments, the power level, the position relative to the atomization hose 270, and other variables of the second heat source 300 may be adjusted by varying the material on the atomization hose 270, And is selected to overheat at a temperature above 50 DEG C to a temperature range of about 400 DEG C above the liquidus line of the material. According to additional embodiments, the power level, position, and other variables of the second heat source 300 may be adjusted such that the material on the atomizing hose 270 is heated to about 200 < RTI ID = 0.0 >Lt; RTI ID = 0.0 > ° C. ≪ / RTI > According to other embodiments, the power level, location, and other variables of the second heat source 300 may be adjusted by changing the chemistry of the molten material in a way that the second heat source 300 does not want and / Unless evaporated, it is optimized to overheat the material to a temperature in excess of the liquidus by any reasonable degree.

According to certain non-limiting embodiments, an atomization device 310 includes an atomization nozzle configured to form a droplet spray of molten material 260, wherein the transfer unit 320 is positioned upstream of the atomization device 310 . For example, the transfer unit 320 may pass the molten material directly to the atomization nozzle. The delivery unit 320 is coupled to the atomization hose 270 and the atomization device 310. The second heat source 300 is configured to maintain the molten material 260 flowing into the transfer unit 320 in a molten state and the transfer unit 320 is configured to transfer at least a portion of the molten material 260 into the molten state of the atomizing hose 270 to the atomization device 310. Although the illustrated apparatus 200 includes only a single delivery unit and only one combination of a single atomization device, it should be understood that embodiments comprising a plurality of atomization devices, for example, a plurality of atomization nozzles, . For example, in a plurality of delivery units 320 and devices using one or more atomization nozzles or other atomization devices 310 located downstream of the atomization hose 270, material production costs may be reduced and the process rate the process rate can be increased.

Turning to FIG. 5, according to the illustrated non-limiting embodiment, the delivery unit 320 is a cold induction guide (CIG). Figure 6 illustrates an apparatus 200 'in accordance with another non-limiting embodiment of the present invention. The delivery unit 320 of the apparatus 200 'optionally includes an induction guide 382 including a CIG 388 as well as a segmented induction mold 386 and an injection bowl 384 . In a non-limiting embodiment of the illustrated apparatus 200 ', an additional heat source 390 is associated with the injection bowl 384 and the segmented induction mold 386.

The transfer unit 320 holds a plurality of molten materials 260 that are passed from the atomizing hose 270 to the atomization apparatus 310 and manufactured in the melting hose 220 by protecting the molten material 260 from the outside atmosphere . In addition, the transfer unit can be configured to prevent the molten material from being contaminated by the oxide that may be generated when using conventional atomization nozzles. The transfer unit 320 can also be used to meter the molten material 260 flowing from the atomization hose 270 to the atomization apparatus 310, as will be described in detail below. It will be appreciated by those skilled in the art that by considering the description herein, the molten material 260 can be adjusted by maintaining the molten state between the atomizing apparatus and the atomizing hose, as used in embodiments of the apparatus and methods of the present invention It would be possible to provide a variety of alternate designs for the delivery unit and its associated devices that can be delivered. All such transfer unit designs that may be incorporated into the apparatus and methods of the present invention are included within the scope of the present invention.

According to certain non-limiting embodiments, the delivery unit 320 includes an inlet 330 adjacent the atomization hose 270 and an outlet 340 adjacent the atomization device 310, A conductive coil 350 is placed in the inlet 330. A current source (not shown) is optionally electrically connected to the electrically conductive coil 350 to heat the molten material 260 such that at least a portion of the molten material 260 begins to flow to the atomization device 310. According to certain non-limiting embodiments, the electrically conductive coil 350 is configured to heat the molten material 260 from a liquid line of material to a temperature range of up to 500 degrees C of the liquid line.

According to certain non-limiting embodiments, the transfer unit 320 includes a melting vessel 360 for receiving the molten material 260, wherein the transfer region of the transfer unit 320 is molten Is configured to include a passageway (370) configured to receive the molten material (260) from the container (360). The walls of passageway 370 are formed by a plurality of fluid-cooled metallic segments. According to certain non-limiting embodiments, the delivery unit 320 includes one or more electrically conductive coils 380 located at the outlet 340. The coils 380 are cooled by circulating a suitable coolant, such as water or another heat-conducting fluid, through the conduit connected to the outlet 340. A portion of the molten material 260 contacts the cooled wall of the passageway 370 of the transfer unit 320 and is cured to form a skull that prevents the wall from contacting the remainder of the molten material 260 It can be insulated. Once the hus wall is cooled and the skull is formed, the inner walls of the delivery unit 320 can be prevented from being contaminated by the materials from which the molten material is formed.

During the time that the molten material 260 flows from the molten container 360 of the transfer unit 320 through the passage 370, the molten material 260 is heated by induction so that current is supplied to the molten material 260 to maintain the molten material in a molten state. And passes through the conductive coil 380. The coil 380 is provided as an induction heating coil and adjustably heat the molten material 260 passing through the outlet 340 of the delivery unit 320. According to certain non-limiting embodiments, the electrically conductive coil 380 may be configured to heat the molten material 260 to a temperature range of about 50 占 폚 above the liquidus line of material to about 400 占 폚 above the liquidus line . In further embodiments, the electrically conductive coil 380 is configured to heat the molten material 260 to a temperature range from the liquidus temperature of the material to about 500 占 폚 above the liquidus line. According to certain other non-limiting embodiments, the electrically conductive coil 380 is configured to selectively prevent the molten material 260 from passing through the atomization device 310. [

According to certain non-limiting embodiments, at least a portion of the molten material 260 is passed continuously to the atomization apparatus 310. In these non-limiting embodiments, the molten material 260 flows continuously from the melting hose 220 to the atomization hose 270 and passes through the delivery unit 320, the outlet 340 of the delivery unit 320, And is then passed into the atomization apparatus 310. [ In certain non-limiting embodiments, the flow of molten material 260 through the atomizing hose 270 may be discontinuous, meaning that there is a start and a stop. In various non-limiting embodiments, the molten material 260 flows from the melting hose 220 to the atomizing hose 270 via one or more additional hoses and is directed through the transfer unit 320 to the transfer unit 320 Outlet 340, and is passed into the atomization apparatus 310. [ According to certain non-limiting embodiments, the atomization apparatus 310 includes an atomization nozzle that includes a plurality of plasma atomization torches converging at one point to form a droplet spray of the molten material 260 . According to further non-limiting embodiments, the atomization nozzles include three plasma torches that are equally distributed and form an angle of about 120 [deg.] With respect to each other. In the above embodiments, each plasma torch may be positioned to form an angle of 30 degrees with respect to the axis of the atomization nozzle. According to certain non-limiting embodiments, the atomization apparatus 310 may include an atomization nozzle (not shown) comprising a plasma jet generated by a DC gun operating at a power range between 20 and 40 kW, . According to certain non-limiting embodiments, the atomization apparatus 310 includes an atomization nozzle that forms one or more gas jets that spray molten material 260 to form a droplet spray.

The droplet spray is directed into the collector 400. According to certain non-limiting embodiments, one position of the collector 400 relative to the atomization nozzle or other atomization device 310 is adjustable. The distance between the collector 400 and the atomization point can control the solid fraction in the material deposited in the collector 400. The position of the collector 400 relative to the atomizing nozzle or other atomizing device 310 is such that the distance between the atomizing nozzle or other atomizing device 310 and the surface of the deposited material in the collector 400 The distance can be adjusted to keep it properly. According to certain non-limiting embodiments, the collector 400 is selected from a chamber, a mold, and a rotating mandrel. For example, in certain non-limiting embodiments, when the material is deposited in the collector 400, the collector 400 may be rotated so that the droplet is more uniformly deposited on one surface of the collector 400 .

It will be appreciated that the device 200 described above can be used to connect the melting hose 220, the atomizing hose 270, the atomizing device 310, the transfer unit 320 and the collector 400 to a relatively separate unit or device connected in series It will be appreciated that the device 200 need not necessarily consist solely of the above method. Instead of consisting of individual and independent melting (and / or melting / reforming), transferring, atomizing, and collector units, a device according to the present invention, such as device 200, Can be integrated into a given area or element, but can not be deconstructed into an individually and independently operable device or unit. Thus, looking at the following claims for melting hoses, atomization hoses, atomization devices, delivery units, and collectors means that these separate units can be separated from the devices claimed in the present invention without losing operability It should not be considered.

In certain non-limiting embodiments, metallic powder prepared according to various non-limiting embodiments of the apparatus described herein or according to various non-limiting embodiments of the methods described herein The material comprises an average particle size of 10 to 150 microns. In certain non-limiting embodiments, metallic powder prepared according to various non-limiting embodiments of the apparatus described herein or according to various non-limiting embodiments of the methods described herein The material has a particle size of 40 to 120 microns (i.e., substantially all of the powder particles have a particle size in the range of 40 to 120 microns). Metallic powder materials having a particle size distribution of 40 to 120 microns are particularly useful for electron beam additive manufacturing applications. In certain non-limiting embodiments, metallic powder prepared according to various non-limiting embodiments of the apparatus described herein or according to various non-limiting embodiments of the methods described herein The material has a particle size distribution of 15 to 45 microns (i.e. substantially all of the powder particles have a particle size in the range of 15 to 45 microns). Metallic powder materials with a particle size distribution of 15 to 45 microns are particularly useful for laser lamination applications. According to certain non-limiting embodiments, the metallic powder material comprises spherical particles. In certain other non-limiting embodiments, at least a portion of the metallic powder material includes other geometric shapes, such as flakes, chips, needles, and combinations thereof But are not limited thereto.

According to certain non-limiting embodiments, the metallic powder material has a composition that can not be readily produced by conventional ingot metallurgy, such as melting and casting techniques. This means that the methods described herein can produce a metallic powder material having a composition that can be separated too easily or prevented from being cast by conventional ingot metallurgy. According to certain non-limiting embodiments, the boron content of the metallic powder material is greater than 10 ppm based on the total powder material weight. In conventional ingot melting and casting techniques, boron levels above 10 ppm can form harmful borides. On the other hand, various non-limiting embodiments of the methods described herein have shown that metallic powder materials with a boron content greater than 10 ppm can be made without harmful phase or properties that are unacceptable I will. Thus, the possibility of forming a metallic powder material that can be produced is expanded.

The metallic powder material produced according to the apparatus and methods of the present invention may have any composition suitably formed using the apparatus and methods of the present invention. According to certain non-limiting embodiments, the metallic powder material may be selected from the group consisting of pure titanium industrial, titanium alloys (e.g., Ti-6Al-4V alloys having a composition specified in UNS R56400), and titanium aluminide alloys 48Al-2Nb-2Cr alloy). According to another non-limiting embodiment, the metallic powder material has a chemical composition material comprising, by weight, about 4% vanadium, about 6% aluminum, balance titanium and impurities. (All percentages herein are% by weight, unless otherwise indicated). According to another non-limiting embodiment, the metallic powder material may be selected from the group consisting of industrial pure nickel, nickel alloys (e.g., alloy 718 with a composition specified in UNS N07718), pure zirconium in industry, zirconium alloys (For example, ATI Nb1Zr ™ alloys (Type 3 and Type 4) having a composition specified in UNS R04261), pure tantalum for industrial use, tantalum alloys (for example, a composition specified in UNS 20255), pure niobium Tantalum-10% tungsten alloy), pure tungsten for industrial use, and a tungsten alloy (e.g., a 90-7-3 tungsten alloy). It will be appreciated that the apparatus and methods described herein are not limited to manufacturing metallic powder materials having the above-mentioned chemical composition. Instead, the starting material can be selected to provide a metallic powder material having the desired chemical composition and other desired properties.

The metallic powder material produced using the method of the present invention and / or the apparatus of the present invention can be produced by a hot isostatic pressing technique and other suitable conventional techniques for forming an article from a metallurgical powder, (E. G., Metal and metal alloys) articles. These and other suitable techniques will be apparent to those skilled in the art from a consideration of the present invention.

It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the appended claims. It will be within the concept and scope of the following claims and the detailed description of the invention. Accordingly, it is to be understood that the invention is not limited to the specific embodiments described or implied herein, but is to be understood as dealing with variations that are within the concept and scope of the invention, as defined in the claims. It will also be appreciated by those skilled in the art that these modifications are possible without departing from the concept of the present invention.

Claims (44)

A method for making a metallic powder material, said method comprising:
Feeding the feed material to the melting hose;
Melting the feed material in the melting hose with a first heat source to provide a molten material;
Passing at least a portion of the molten material directly or indirectly from the melting hose to the atomizing hose;
Heating the molten material in the atomization hose as a second heat source;
Passing at least a portion of the molten material from the atomizing hose to the atomizing nozzle in a molten state; And
Forming a droplet spray of a molten material with an atomizing nozzle, wherein at least a portion of the droplet spray is cured to provide a metallic powder material. The method of claim 1, wherein at least a portion of the molten material is passed through the at least one additional hose from the melting hose prior to entering the atomizing hose. The plasma display device according to claim 1, wherein the first heat source and the second heat source each include at least one of a plasma torch, an electron beam generator, a heater for generating electrons, a laser, an electric arc device, and an induction coil ≪ / RTI > The method of claim 1, wherein the molten material is modified or homogenized prior to passing through the atomizing nozzle. The method of claim 1, further comprising passing at least a portion of the molten material through the cold induction guide upstream of the atomization nozzle. 6. The method of claim 5, wherein the cold induction guide comprises an inlet adjacent the atomization hose and an outlet adjacent the atomization nozzle, wherein the electrically conductive coil is located at the inlet and heats the molten material to transfer at least a portion of the molten material from the atomization hose ≪ RTI ID = 0.0 > 8. ≪ / RTI > 7. The method of claim 6, wherein the electrically conductive coil is configured to heat the molten material from a liquidus line of material to a temperature range of up to 500 DEG C of the liquidus line. 6. The method of claim 5, wherein the cold induction guide is configured to include an inlet adjacent the atomization hose and an outlet adjacent the atomizing nozzle, wherein the electrically conductive coil is positioned at the outlet and the melted material is adjustably heated. ≪ / RTI > 9. The method of claim 8, wherein the electrically conductive coil is configured to heat the molten material from a liquidus line of material to a temperature range of up to 500 DEG C of the liquidus line. 6. The apparatus of claim 5, wherein the cold induction guide is configured to include an inlet adjacent the atomization hose and an outlet adjacent the atomization nozzle, wherein the electrically conductive coil is located at the outlet and stops passing molten material through the atomization nozzle A method for manufacturing a metallic powder material. The method of claim 1, wherein the atomizing nozzle comprises a plurality of plasma atomization torches, wherein the plurality of plasma atomization torches converge at a point and form a plasma jet that forms a droplet spray from the molten material. ≪ / RTI > 2. The method of claim 1, wherein the atomizing nozzle forms one or more gas jets that inject the molten material into the droplet spray. The method of claim 1, wherein at least a portion of the molten material is passed continuously through an atomizing nozzle. The composition of claim 1, wherein the composition of the metallic powder material is selected from the group consisting of pure titanium for industrial use, titanium alloy, titanium aluminide alloy, pure nickel for industrial use, nickel alloy, pure zirconium for industrial use, zirconium alloy for industrial use, pure niobium for industry, pure tantalum for industrial use, Alloys, pure tungsten for industry, and tungsten alloys. The method of claim 1, wherein the composition of the metallic powder material comprises a boron content of greater than 10 ppm. The method of claim 1, wherein the composition of the metallic powder material comprises, by weight, about 4% vanadium, about 6% aluminum, balance titanium and impurities. The method of claim 1, wherein the average particle size of the metallic powder material is between 10 microns and 150 microns. The method of claim 1, wherein the particle size distribution of the metallic powder material is between about 40 microns and about 120 microns. The method of claim 1, wherein the particle size distribution of the metallic powder material is between 15 microns and 45 microns. A metallic powder material produced by the method for manufacturing a metallic powder material according to claim 1. 21. The method of claim 20, wherein the composition of the metallic powder material is selected from the group consisting of pure titanium for industrial use, titanium alloy, titanium aluminide alloy, pure nickel for industrial use, nickel alloy, pure zirconium for industrial use, zirconium alloy for industrial use, pure niobium for industrial use, Alloys, pure tungsten for industrial use, and tungsten alloys. 21. The metallic powder material of claim 20, wherein the composition of the metallic powder material comprises, by weight, about 4% vanadium, about 6% aluminum, balance titanium and impurities. 21. The metallic powder material of claim 20, wherein the average particle size of the metallic powder material is between 10 microns and 150 microns. 21. The metallic powder material of claim 20, wherein the metallic powder material has a particle size distribution of between about 40 microns and about 120 microns. 21. The metallic powder material of claim 20, wherein the particle size distribution of the metallic powder material is between 15 microns and 45 microns. 21. The metallic powder material of claim 20, wherein the metallic powder material comprises a boron content of greater than 10 ppm. An apparatus for producing a metallic powder material, said apparatus comprising:
A melting hose configured to receive a feed material;
A first heat source configured to melt the feed material to provide a molten material;
An atomizing hose arranged to receive directly or indirectly at least a portion of the molten material from the melting hose;
A second heat source configured to heat the molten material in the atomization hurdle;
An atomizing nozzle configured to form a droplet spray from the molten material;
An atomizing hose and a delivery unit coupled to the atomization nozzle, the delivery unit being configured to pass the molten material from the atomization hose to the atomization nozzle in a molten state; And
And a collector configured to receive a droplet spray. ≪ RTI ID = 0.0 > 11. < / RTI > 28. The apparatus of claim 27, further comprising one or more additional hoses arranged and in communication with each other between the melting hose and the atomizing hose. 29. The apparatus of claim 28, wherein the melting hose, the atomizing hose, and the at least one additional hose are in line. 29. The method of claim 28 wherein the melting horse, the atomizing horse, and the at least one additional horse are arranged spaced apart in a pattern selected from a jig-jag, L-shape, and C- Device. 29. The apparatus of claim 28, wherein at least one of the melting hose, the atomizing hose, and the at least one additional hose is configured to modify or homogenize the molten material. 28. The apparatus of claim 27, wherein the first heat source is connected to the melting hose and the second heat source is connected to the atomizing hose. 36. The plasma display panel of claim 32, wherein the first heat source and the second heat source each include at least one of a plasma torch, an electron beam generator, a heater for generating electrons, a laser, an electric arc device, and an induction coil ≪ / RTI > 29. The apparatus of claim 28, wherein the additional heat source is coupled to the at least one additional hose, wherein the additional heat source comprises at least one of a plasma torch, an electron beam generator, a heating device to generate electrons, a laser, an electric arc device, ≪ / RTI > 28. The apparatus of claim 27, wherein the delivery unit comprises a cold induction guide. 36. The method of claim 35, wherein the cold induction guide comprises an inlet adjacent the atomization hose and an outlet adjacent the atomizing nozzle, wherein the electrically conductive coil is located at the inlet and heats the molten material to pass at least a portion of the molten material to the atomizing nozzle Wherein the metallic powder material is configured to start at least a portion of the metallic powder material. 37. The apparatus of claim 36, wherein the electrically conductive coil is configured to heat the molten material from a liquidus line of material to a temperature range of up to 500 < 0 > C above the liquidus line. 36. The method of claim 35, wherein the cold induction guide is configured to include an inlet adjacent the atomization hose and an outlet adjacent the atomization nozzle, wherein the electrically conductive coil is positioned at the outlet and the melted material is adjustably heated Apparatus for manufacturing materials. 39. The apparatus of claim 38, wherein the electrically conductive coil is configured to heat the molten material from a liquidus line of material to a temperature range of up to 500 DEG C of the liquidus line. 39. The method of claim 38, wherein the cold induction guide is configured to include an inlet adjacent the atomization hose and an outlet adjacent the atomization nozzle, wherein the electrically conductive coil is located at the outlet and stops passing molten material through the atomization nozzle An apparatus for manufacturing a metallic powder material. 28. The method of claim 27, wherein the atomizing nozzle comprises a plurality of plasma atomization torches, wherein the plurality of plasma atomization torches converge at a point and form a plasma jet that forms a droplet spray from the molten material. Lt; / RTI > 28. The apparatus of claim 27, wherein the atomizing nozzle forms one or more gas jets that inject the molten material into the droplet spray. 28. The apparatus of claim 27, wherein the position of the collector relative to the atomizing nozzle is adjustable. 28. The apparatus of claim 27, wherein the collector is selected from a chamber, a mold, and a rotating mandrel.

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